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OLED
2008. 8. 26.
Sunic System, Ltd.#333-1, Wonchon-dong, Paldal-gu, Suwon, Korea
Tel.: +82-31-217-4477, Fax.:+82-31-217-4476
www.sunicsystem.com
Yeong-Ho Park
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Contents
I. OLED -. OLED Device & Products-. OLED Technology & Roadmap
II. OLED System & Issues of Next OLED System1) Patterning Method2) Deposition Method3) Glass(Mask) Moving Method4) Encapsulation Method5) Factory Automation
III. Summary
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OLED : OLED Products
Sony 11 OLED TV Mobile-phone ( CYON, )
- - Glass - - - ()- etc.
- Thin- Fast Response- Wide Viewing Angle- Natural Color- Low Power- etc.
OLED OLED
OLED Lighting
I. OLED
4
OLED : OLED Market
World wide OLED panel market
-
1,000
2,000
3,000
4,000
5,000
6,000
7,000
2006 2007 2008 2009 2010
Re
ve
nu
e (
Mili
US
$)
AM OLED
PM OLED
: 2008 OLED panel panel 15% , 2009 4.5, 2010 8.7 , .
OthersOthersOthersOthers3.2%3.2%3.2%3.2%JapanJapanJapanJapan28.9%28.9%28.9%28.9%
TaiwanTaiwanTaiwanTaiwan21.1%21.1%21.1%21.1% KoreaKoreaKoreaKorea46.8%46.8%46.8%46.8%O thersO thersO thersO thers2.9%2.9%2.9%2.9%
KoreaKoreaKoreaKorea52.8%52.8%52.8%52.8%JapanJapanJapanJapan24.3%24.3%24.3%24.3%TaiwanTaiwanTaiwanTaiwan20.0%20.0%20.0%20.0%OLED Panel Revenue
Q4 07 Q1 08
KOREA : World leading OLED Panel Player after next 3 year?
Q1 10
Korea OLED ? OLED ?
: 2008
I. OLED
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OLED : OLED Market 1. -. , OLED -2.5 100 ...
( 2008. 7. 23.)-. -, OLED ( 2008. 7. 11.)
, , (OLED) 10 . 35 . 2012 OLED TV 20, 300 . LCD TV 20% 5050, PDP TV 35% 880 .
-. OLED
2. - AM OLED ' '
CMO AM OLED . CMEL2.8 AM OLED 30 , 100 . ( 2008. 7. 1)
3. -. 2008 OLED -. 2008 Micro-Display -. in-line OLED manufacturing equipment and related Processes from UDT(Jilin) Co.(April 16, 2007)
4. -. OLED , Signage (OLLA Project)-. 08 OLED
I. OLED
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( , 2007) I. OLED
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OLED (I) (2007)I. OLED
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OLED Life Cycle (2007)I. OLED
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OLED Process Sequence (TFT, PM-OLED)
Pattern (VII)
ITO Pattern (VI)
ITO Depo
Via Pattern (V)
Interlayer Depo
LTPS-Si TFT
SiO2/-Si
Poly Si(ELA)
Poly-Si Pattern (I)
Gate Ox/Metal
Gate Pattern (II)
SiN
SiN Pattern (III)
S/D Metal
S/D Pattern (IV)
ELA
4th
i) ITO, Cr
substrateii) ITO, Cr
Patterning
iii) Insulator
formation
iv) Cathode
separator
ix) Metal Depo x) Encapsulation xi) Testing
v) Plasma Treatment
vi) HIL/ HTL Depo
viii) ETL/EIL Depo
vii) RGBBDepo
xii) Drive IC Bonding
Array Process : Photo-Etching
Depo & Encap. in OLED Equipment
Glass substrate
TFT AM-OLED PM-OLED
I. OLED
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Mono/Area Color
2000 ~ 2002
Full Color (1~5)
2006 ~
PMOLED/Pilot PMOLED/Mass AMOLED()
Sunics OLED R&D History
Full Color (1~10)
2003 ~ 2005
Full Color (>10)
2008 ~
AMOLED()
-. -. -. , -.
, -. -. -. -.
, -. Mobile-. ()-. -.
-. -. -. (, C/F )-. .
II. OLED System
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(OLED : SUNICPlus 200) from Sunic System
OLED System : R&D System : 200200 OLED systemII. OLED System
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High quality !High quality !High quality !High quality !High reducibility !High reducibility !High reducibility !High reducibility !High stability !High stability !High stability !High stability !
Low running cost ! Low running cost ! Low running cost ! Low running cost !
PMOLED AMOLED
(OLED : SUNICPlus 400) from Sunic System
OLED System : Mass Product System : Gen 2 OLED systemII. OLED System
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1. Process Chamber
& Vacuum System-. Chamber
-. Mechanical Pump
-. High Vac. Pump
-. Gate V/V
-. Shutter
2. Aligner-. CCD Camera
-. Lens
-. Lighting
-. PC w/ Grab Board
-. Shadow Mask
3. Evaporation Cell-. Host Cell
-. Dopant Cell
-. Power Supplier
4. Thickness Control System-. Crystal Sensor
-. Sensor Head
-. Thickness Controller
OLED System : FMM
Cryo
Pump
Mechanical Pump
CCD
Glass
Mask
Shutter
THK Monitor Sensor
Cell
Host Dopant
G/V
THK Sensor Contr
Motor
Aligner
ThicknessMonitor
Cell
Vacuum System
II. OLED System
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OLED System : OLED 1. OLED ,
, , RGB , line .
2. nm .: , Particle,
3. : , Plasma Thermal
4. 5. 6. 7. Photo Fine Metal Mask Patterning
: Auto-Aligning
II. OLED System
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Source Moving Source Moving
BufferBufferBufferBufferLoaderLoaderLoaderLoader TMTMTMTM(1)(1)(1)(1)HILHILHILHILP/TP/TP/TP/THTLHTLHTLHTL MASKMASKMASKMASKLoadiLoadiLoadiLoadingngngng BuffeBuffeBuffeBufferrrrTMTMTMTM(2)(2)(2)(2)GreenGreenGreenGreenRedRedRedRedMASKMASKMASKMASK BlueBlueBlueBlue TMTMTMTM(3)(3)(3)(3) BufferBufferBufferBufferEILEILEILEILBLBLBLBLMetal 1Metal 1Metal 1Metal 1 MASKMASKMASKMASK TMTMTMTM(4)(4)(4)(4) BufferBufferBufferBufferTCO 1TCO 1TCO 1TCO 1Metal 2Metal 2Metal 2Metal 2MASKMASKMASKMASK TCO 2TCO 2TCO 2TCO 2HIL HTL EML EML EML ETL EIL MetalP/TL/L U/L
Cluster : Gen2, Half Gen4 system- 2~4 -
In-line : Over Gen4 ?- 4
Next OLED System : Cluster vs. In-line
- 2 ~ 4 - - , - Fine Metal Mask Patterning
4G VerticalR&DANS
2, Half 3.5G
?2G VerticalApplied Films
> 5G2GULVAC> 5G2G, Half 4G> 5G2G, Half 4GTOKKI
II. OLED System
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Patterning : RGB Patterning TechnologyShadow mask
Red
ITO glass
Green Blue
Tolerance Design in Shadow Mask Patterning1) ITO Patterning(Photo/Etching)
2) Mask Tolerance during Making
3) Strain for Tensioning, Mask Design
4) Aligning Accuracy for Aligning
5) Magnet Design, Glass & Mask Distortion,
Shadow Effect for Deposition
6) Thermal Expansion Shadow Mask Shadow Mask Shadow Mask Shadow Mask MaskMaskMaskMask
1) Patterning Method
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((((Lens)Lens)Lens)Lens)
LightLightLightLight
((((CCD)CCD)CCD)CCD)
X,Y,T,Z,M
Maskaligner Key
GlassAligner Key
Shadow MaskShadow MaskShadow MaskShadow Mask GlassGlassGlassGlass Align KeyAlign KeyAlign KeyAlign Key Patterning : Auto-Aligning Module from Sunic OLED System
1) Patterning Method
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Half 4G Aligner
Auto-aligner : align accuracy test
Align accuracy : < 3.5 um (avg. 1.8 um) @ 100 times Align time : < 42 sec (avg. 30.5 sec)
Patterning : Auto-Aligning Module from Sunic OLED System1) Patterning Method
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Pixel Alignment Tolerance Factor Invar mask(2G) SUS mask(5G)Glass Patterning Tolerance (Position) 3 3 Patterning Mask Mask Slot Size Tolerance (Width) 5 5 Mask
Stretching Tolerance (Position) 10 15 Tension Machine Mask Aligning Tolerance (Position) 5 5 Auto-Aligner
Shadow mask Effect (Width) 4 8 * Mask Slope Mask Deformation (Position) 5 30 **
Total Pixel Alignment Tolerance 14 35
Mask Slot Mask Slot Mask Slot Mask Slot
Shadow Effect Shadow Effect Shadow Effect Shadow Effect Pattern Pattern Pattern Pattern
Glass
Mask
=i
TT
1. 2G invar Mask Invar 1~1.5 * 10E-6/Mask 10 -> 1.5E-6/ * 10 * sqrt(370^2+470^2)/2 = 4.5
2. 5.5G SUS 400 Mask SUS 400 10E-6/Mask 5 -> 10E-6/ * 5 * sqrt(1500^2+1850^2)/2 = 59 => => => => Patterning Patterning Patterning Patterning
* Mask Shadow Effect ** SUS 50% Pattering .=> => => => Mask Mask Mask Mask 30%30%30%30% SUSSUSSUSSUS Space Space Space Space 75757575 70707070ppippippippi MaskMaskMaskMask MaskMaskMaskMask Pattern Pattern Pattern Pattern ....
Patterning : Tolerance Design of FMM1) Patterning Method
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255
255 50 (?) 5035
205Pixel dimension = 33% Mask Deformation 20 .
Mask SUS Pattern .
Patterning : How to Make Large Fine Metal Mask
635
635 80 (?)80185
555Pixel dimension = 54%Mask SUS .
a) 40inch (40 ppi) b) 14inch (100 ppi)
1) Patterning Method
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Patterning :
(a) FMM
(c) Inkjet
(b) Laser Patterning
(d) White+C/F
1) Patterning Method
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worseworsenormalBest/polymerPolymer/smallSmallSmall-Molecularmaterial
Low (?)middle (?)middle (?)Expensive(?)CostworsenormalnormalgoodMiddleLowExcellent (?)High~60%70~80%~80%40-50%(Top)
? (Easy, but ?)? (Easy, but ?)< 2min (Fast)~ 4min (Slow)Tact TimeEasyMiddleEasyHard (?)
Linear : < 40%Linear : < 40%Linear : >30%~80%
Point 5%>Point : < 5%Point : < 4%Material usage~200ppi>200ppi>200ppi~150ppi+/- 15um+/- 2.5um+/- 2.5um+/- 20umGen 4 (R&D)Gen 4 (R&D)Gen 4 (R&D)Half Gen 4()()
Ink-jetLaser PatterningWhite+C/FFMM(Evaporation)
Patterning : 1) Patterning Method
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CS
PCR
Glass Ratation
Deposition : Single-point source- - 2 - - -
Multi-point source- - half 4 - - - - TOKKI half 4
Source Moving
Deposition Method
2) Deposition Method
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VerticalHorizontal
-. Difficult D/R Control -. High Temp Increment
-. Particle Issues
-. Doping Ratio
-. Charging Problem of EL Material -. Reliability -. Bad Uniformity along to Cell Direction-. Thermal Effect to Shadow Mask
to Short Distance btn Glass & mask
-. Many Cells for LargeSize
-. Difficult D/R Controlfor Multi-Cell
-. Low Materials Utilization
-. High D/R
-. Short Process Time
-. Good Uniformity
-. D/R : > 20 A/s
- .Easible to Large Size Glass
-. High Material Utilization
-. D/R : 5~20 A/s
-. Conformed forMass Production
-. Easy D/R Control
-. D/R : < 5 A/s
Area CellLinear Cell Point Cell
Deposition : Evaporation Source for Large Area Glass
Source/Glass MovingSource/Glass MovingNo Source/Glass Moving
2) Deposition Method
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370 x 470 mm2 Cell (Sunic System, Ulvac, YAS)
Deposition : Linear Source for Large Glass Size
KVIS by Kodak
VES 400 (Applied Films)
2) Deposition Method
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- Thickness Unif : < 5.0 % - Efficiency of material : 37.8%@ Test Condition : D/R : 7 A/s, CS :300mm
Deposition : Properties of Linear Cell from Sunic OLED System
- Dep. rate : host 3/s, dopant 0.015/s- Doping Ratio : 0.5%(200:1)
Doping uniformity test
T : 4.5 with cooling, T : 25 without cooling@ 3 hrs deposition, 13.2/smm, CS 100 mm
Mask temperature rising test
Center Center Center Center
EdgeEdgeEdgeEdge
-.Scan Shadow : * 3~ 4um -. Nozzle Shadow : * inside : ~9.5um
* Outside : 10~11um
2) Deposition Method
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Deposition : Material Utilization from Sunic OLED System
Cell Glass glass cell
Material Utilization
Glass Size
Distance from Source to Glass
Cell Type (Point, Linear, Area, etc)
Cell Design
Etc.
Linear cell : horizontal
2) Deposition Method
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Deposition : Metal Evaporation CellMetal source
- , - - , , -
Revolver () () Vertical Metal Cell
2) Deposition Method
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OVPD(Organic Vapor Pressure
Deposition)
-. Top-Down Type Deposition
-. No Glass Bending
-. Particle Issue
-. Thermal Damage
Ref. S. Hartmann, SID 06 Digest, P1563
Ref. OLEDs 2005 Conference
Deposition : Area Source for Large Glass Size 2) Deposition Method
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Glass
Mask
GlassGlassGlassGlass
MaskMaskMaskMask
Next OLED System :
- - - Align
3) Glass Moving
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Next OLED System : Cluster Tool System Configuration for FMM
MSMSMSMS
PTPTPTPT HILHILHILHIL
BFBFBFBF
HTLHTLHTLHTL
MSMSMSMS
GGGG
BBBBRRRR
BFBFBFBF
MSMSMSMS
EIL/MC# 1EIL/MC# 1EIL/MC# 1EIL/MC# 1ETLETLETLETL EIL/MC# 2EIL/MC# 2EIL/MC# 2EIL/MC# 2
BF#1BF#1BF#1BF#1 BF#2BF#2BF#2BF#2
32323232MMMM
11
11
11
11MM MM
BFBFBFBF BFBFBFBF
----. . . . Application : RGB Full Color
-. TACT Time : ~ 4min-. : min. 21ch-. Dimension (for 5G): 32 (L)x 11(W) x 3.5(H)
(1) Can Aligning by Fine Mask(2) Mask (for RGB)(3) Mask Aligning(4) Sequence .(5) Mask . (6) Mask .
(1) Type : Cluster Type(2) Horizontal or Vertical Moving (3) Vertical Deposition(4) TACT Time : ~ 4min(5) Dimension : 16M(L)*2M(W)
.
3) Glass Moving
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GULLGULLGULLGULLGULLGULLGULLGULLMask ReturnMask ReturnMask ReturnMask Return
PTPTPTPTPTPTPTPT HILHILHILHILHILHILHILHILLL(HV)LL(HV)LL(HV)LL(HV)LL(HV)LL(HV)LL(HV)LL(HV)LL(LV)LL(LV)LL(LV)LL(LV)LL(LV)LL(LV)LL(LV)LL(LV) HTLHTLHTLHTLHTLHTLHTLHTL EML(R)EML(R)EML(R)EML(R)EML(R)EML(R)EML(R)EML(R) OIC(N)OIC(N)OIC(N)OIC(N)OIC(N)OIC(N)OIC(N)OIC(N) OIC(P))OIC(P))OIC(P))OIC(P))OIC(P))OIC(P))OIC(P))OIC(P))ETLETLETLETLETLETLETLETL HTLHTLHTLHTLHTLHTLHTLHTL EML(G)EML(G)EML(G)EML(G)EML(G)EML(G)EML(G)EML(G) OIC(N)OIC(N)OIC(N)OIC(N)OIC(N)OIC(N)OIC(N)OIC(N) OIC(P))OIC(P))OIC(P))OIC(P))OIC(P))OIC(P))OIC(P))OIC(P))ETLETLETLETLETLETLETLETL HTLHTLHTLHTLHTLHTLHTLHTL EML(B)EML(B)EML(B)EML(B)EML(B)EML(B)EML(B)EML(B) ETLETLETLETLETLETLETLETL MCMCMCMCMCMCMCMC----. . . . Application : White Color Application : White Color Application : White Color Application : White Color ----. TACT Time : < 2min. TACT Time : < 2min. TACT Time : < 2min. TACT Time : < 2min----. . . . : : : : min 27chmin 27chmin 27chmin 27ch----. . . . Dimension : Dimension : Dimension : Dimension : (for 5G): 85 (L)x 2(W) x 3.5(H)
(1) TACT Time(2) Mask (for White)(3) Glass/Mask Moving
(4) Sequence (5) Mask / Tray moving (6)
(1) Type : In-Line (2) Vertical Moving (3) Vertical Deposition(Glass Scan)(4) TACT Time : < 2min(5) Dimension : 16M(L)*2M(W)(6) Glass Size .
.
3) Glass MovingNext OLED System : Inline System Configuration for White OLED
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( )
or or
VerticalVertical
- -Particle -Particle
-X
Face up
AxitronXX
Face up
or 100kg Robot Mask
- -Moving - Scale Up
- -, mask -Particle -
-, mask -
X Sunic, ANSNessTOKKI(730x460)
Particle
or Robot
Throughput
VerticalVertical
XMask/glass
( )Lay out
Face downHorizontal
In - LineCluster
Face downDep. MethodHorizontalMoving
Next OLED System : Cluster vs. In-line3) Glass Moving
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1. Metal or Glass CAN
Glass substrate
4. Thin Film Passivation
Glass substrate
3. Polymer Sheet
Glass substrate
Polymer
2. Glass Sheet
Glass substrate
Glass Sheet
OLED Encapsulation SystemEncapsulation
- top emission, OLED , - thin film encapsulation
4) Encapsulation
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DegasSealant
Dispensing
DesicantAttaching
Cover
Glass
Loading
N2
Replace
Plasma or
UV Cleaning
PanelBuffer
TM
Encap
Assy
Unload
Encap Glass Moving DirectionPanel Glass
Moving Direction
OLED Panel
OLED Encapsulation System : Encapsulation Process1. Substrate size : 370 x 470
2. Production type : Mass production
3. Customer : Korea PMOLED manufacturing company
4) Encapsulation
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OLED Encap System : next encapsulation technologies
Ceramic LayersIsolation Layers
Glass Substrate
Barix coatingActive OLED
System Configuration for Barix Encapsulation
Isolation Layers : stress release, planerization
Max Depo. Temp : < 80Ceramic Layers : protection from moisture, oxygen
Thin film encapsulation (Barix licensed from Vitex Co.)
4) Encapsulation
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TMC
CTC
PMCPMCPMC PMC
TMC TMC
TCP/ IP Network
TCP/ IP Network
PC for data real-time viewer
Automation : Computer control : user friendly system
CTC Screen TMC Screen
PMC Screen Config.Screen
5) Factory Automation
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Main Issues for Next Generation OLED Equipment1. Why to develop for Large Size OLED Equipment System
: Which is OLED Technical Direction & Method?-. RGB vs. White OLED-. Cluster Type vs. Inline Type-. Face Up/Down vs Vertical Deposition-. Encapsulation Method
2. What to obtain Profit for OLED Equipment-. High R&D Cost in competition area for Small Market Size-. High R&D Cost in Multi-Process (Organic Depo, Metal Depo, Encap, etc)-. Complicated System : Deposition + Aligner included Shadow Mask
+ Thickness Monitoring -. Component Cost & Reliability3. OLED Display and/or OLED Lighting
-. Whos Leader in OLED Display and/or OLED Lighting?-. Whats Next Technical?
4. Whos Frontier to develop in OLED Equipment -. Who(Whos company) can make the profit to develop in OLED Equipment?-. Who(How) is invest to develop Next OLED Equipment?
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Current Technology for OLED Mass Production1. Max Glass Size : 730*460 mm22. Reliable Equipment : 370*470 mm2 Glass Size
- Resolution : < 150 ppi (>150ppi : R&D Level)- TACT Time : 4~6min- Doping Level : 200:1- Panel Size : 1~5- EL material Efficiency : ~ 5%
Next Technology for OLED Mass Production1. Glass Size : > 1100*1300 mm2 (need New Concept H/W)2. Panel Size & Resolution : 1~40 QVGA, VGA
or White OLED3. TACT Time : 2 ~ 6min4. EL material Efficiency : over 30%5. RGB Shadow Mask Size : ? (strategic investment)
Summary
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Whos Success
in OLED Business ?
Thank you for your attention
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